A Total Solution for Automotive Helical Spring Design

Transcription

1 A Total Solution for Automotive Helical Spring Design APM Engineering & Research Sdn. Bhd. BON KOK WUI & TAN MING SHENG Date 27 th August, 2013

2 Company Background : APM Engineering & Research Sdn. Bhd. Suspension System Range of coil, leaf and parabolic springs, air bellow. Shock absorbers. Corner Module. Complete Leaf Spring Suspension Module. Gas Spring Seating Systems Complete Seating System from OEM RFQ. New seating mechanisms (Track, Recliner, Height adjustment, Lumbar etc). Climate Control Radiator, Condenser cores and assembly. Blower fan and shroud. Complete A/C Cooling module. Interiors and Plastics Door Panel and Interior trims & head liners. Instrument Panel, Bumper System 2

3 Introduction Current automotive design trend: Better Fuel Efficiency & Larger Cabin Space. Consequences: Suspension design package reduced, complexity of design increased. Design process become more complex due to the limitation of the design package. More and more consideration is required which is unable to capture by general design formulation. CAE as a design tool to realize design blind spot and provide better understanding to the designer through virtual realization 3

4 Objectives To simulate coil spring behavior along the working stroke during design stage in order to detect the potential risk prior to prototype making. To evaluate Coil Spring design based on below criteria along the working stroke: Load & Spring Constant Principle Stresses & Shear Stresses Interference with Surrounding Package Rubber Force distribution 4

5 Methodology Customer Input Feasibility Study No Preliminary Design Calculation No CAD Drawing Computer Aided Engineering (CAE) Load Analysis Stress Analysis Rubber Force Analysis Interference Analysis No Generate FEA Report Customer Approval Drawing and Design information for prototype Sample Development 5

6 Model & Load Case Description Fixed Coil Spring [Steel] 3D Spring Seat [Steel] 2D Rubber Seat [Rubber] 3D Imposed Displacement Surrounding Packages [Steel] 2D In Vehicle Condition : Upper seat is fixed in ALL degree of freedom. Displacement is imposed on the lower seat. 6

7 Detailed Analysis Result : Load & Rate Plots 7

8 Detailed Analysis Result : Principle & Shear Stress Principle Stress Shear Stress 8

9 Detailed Analysis Result : Interference with Surrounding Packages Iso View Bottom View Cross-section View 9

10 Detailed Analysis Result : Interference with Surrounding Packages Mating Parts Dust Cover Rubber Seat Spring Seat 10

11 Detailed Analysis Result : Interference with Surrounding Packages Mating Parts Dust Cover Rubber Seat Spring Seat 11

12 Detailed Analysis Result : Rubber Force Distribution 12

13 Conclusions From the simulation, the potential risk is identified. Therefore design changes can be made during the initial design stage. A full picture of helical spring behavior along the working stroke is illustrated through simulation to enable design engineer for a better judgement ensuring fulfillment of customer s requirement. CAE provides a total solution for automotive helical spring. Not only a higher efficient and comprehensive tool, it is also an enhancement for the helical spring design process. 13

14 Acknowledgements Special thanks to those who contributed in this study: APM Engineering & Research Management & Staff APM Coil Springs Management & Staff Altair Engineering Mr Vishal Pawar Mr Mangesh Gite